BRAKE BOOSTER INSTALLATION

TEMPORARILY INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
1. Install the lock nut and brake master cylinder push rod clevis to the brake booster assembly.
  
  Tech Tips
  
  Tighten the lock nut after adjusting the brake pedal height.
INSTALL BRAKE BOOSTER GASKET
1. Install a new brake booster gasket to the brake booster assembly.
INSTALL BRAKE BOOSTER ASSEMBLY
1. Install the brake booster assembly to the body with the 4 nuts. Tighten the 4 nuts uniformly in alphabetical order.
  
  Torque:
  
  18 N*m { 178 kgf*cm, 13 ft.*lbf }
  
  Note
  
  Do not damage the brake lines or fuel lines.
INSTALL FRONT BRAKE LINE
1. for LHD:
  1. Install the brake tube to the brake actuator bracket with a new clamp.
  2. Using a union nut wrench, connect the 2 brake tubes to the 2-way.
    
    Torque:
    
    15 N*m { 155 kgf*cm, 11 ft.*lbf }
    
    Note
    
    Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
  3. Install the brake tube to the body with 2 new clamps.
  4. Attach the grommet to the body.
  5. Using a union nut wrench, connect the brake tube to the front flexible hose RH while holding the flexible hose with a wrench.
    
    Torque:
    
    15 N*m { 155 kgf*cm, 11 ft.*lbf }
    
    Note
    
    Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
  6. Using a union nut wrench, connect the brake tube to the front flexible hose LH while holding the flexible hose with a wrench.
    
    Torque:
    
    15 N*m { 155 kgf*cm, 11 ft.*lbf }
    
    Note
    
    Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
  7. Install the clamp with the bolt.
    
    Torque:
    
    8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. for RHD:
  1. Install the brake tube to the brake actuator bracket with a new clamp.
  2. Install the brake tube to the body with a new clamp.
  3. Using a union nut wrench, connect the 2 brake tubes to the 2-way.
    
    Torque:
    
    15 N*m { 155 kgf*cm, 11 ft.*lbf }
    
    Note
    
    Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
  4. Install the brake tube to the body with a new clamp.
  5. Attach the grommet to the body.
  6. Using a union nut wrench, connect the brake tube to the front flexible hose RH while holding the flexible hose with a wrench.
    
    Torque:
    
    15 N*m { 155 kgf*cm, 11 ft.*lbf }
    
    Note
    
    Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
  7. Using a union nut wrench, connect the brake tube to the front flexible hose LH while holding the flexible hose with a wrench.
    
    Torque:
    
    15 N*m { 155 kgf*cm, 11 ft.*lbf }
    
    Note
    
    Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
  8. Install the clamp with the bolt.
    
    Torque:
    
    8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL CHECK VALVE GROMMET
1. Install a new check valve grommet to the brake booster assembly.
INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY
1. Install the vacuum check valve assembly to the brake booster assembly.
CONNECT VACUUM HOSE
1. Connect the vacuum hose with the clip.
INSTALL PUSH ROD PIN
1. Text in Illustration
  
  *1 Lithium soap base glycol grease
  
  Apply lithium soap base glycol grease to the push rod pin.
2. Connect the brake master cylinder push rod to the brake pedal with the push rod pin and install a new clip as shown in the illustration.
INSTALL BRAKE PEDAL RETURN SPRING
1. Install the brake pedal return spring between the brake pedal support sub-assembly and brake master cylinder push rod clevis.
INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
1. Install the brake master cylinder sub-assembly Click here.
INSTALL BRAKE ACTUATOR ASSEMBLY
1. Install the brake actuator assembly Click here.
INSTALL ENGINE ASSEMBLY
1. for 1ZR-FAE:
  
  Install the engine assembly Click here.
2. for 2ZR-FAE:
  
  Install the engine assembly Click here.
3. for 1AD-FTV:
  
  Install the engine assembly Click here.
4. for 2AD-FHV:
  
  Install the engine assembly Click here.
REMOVE CENTER COWL TOP VENTILATOR LOUVER
1. Slide the hood to cowl top seal and detach the clip as shown in the illustration.
2. Detach the 5 claws and remove the center cowl top ventilator louver.
BLEED BRAKE SYSTEM
1. Bleed brake master cylinder
  Note
  
  If the master cylinder is reinstalled or if the reservoir becomes empty, bleed the master cylinder.
  
  To prevent brake fluid from damaging painted surfaces, cover any surrounding parts with a piece of cloth.
  1. Remove the brake master cylinder reservoir filler cap assembly.
  2. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
    
    Brake fluid
    
    SAE J1704 or FMVSS No, 116 DOT 4
  3. Using a union nut wrench, disconnect the 2 brake lines from the master cylinder.
  4. Slowly depress the brake pedal and hold it.*1
  5. Cover the 2 outer holes with fingers and release the brake pedal.*2
  6. Repeat *1 and *2 3 or 4 times.
  7. Using a union nut wrench, connect the 2 brake lines to the master cylinder.
    
    Torque:
    
    20 N*m { 199 kgf*cm, 14 ft.*lbf }
    
    Note
    
    Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
2. Bleed brake line
  1. Remove the bleeder plug cap.
  2. Connect a vinyl tube to the bleeder plug.
  3. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1
  4. When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
  5. Repeat *1 and *2 until all the air in the fluid is completely bled out.
  6. Tighten the bleeder plug completely.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
  7. Install the bleeder plug cap.
  8. Repeat the above procedure for each wheel to bleed the brake line.
3. Bleed brake actuator (w/ VSC)
  
  Note
  
  After bleeding the brake system, if the specified height or feel of the brake pedal cannot be obtained, bleed the brake actuator assembly with the intelligent tester by following the procedure below.
  1. Depress the brake pedal more than 20 times with the ignition switch off.
  2. Connect the intelligent tester to the DLC3.
  3. Turn the ignition switch to ON.
    
    Note
    
    Do not start the engine.
  4. Enter the following menus: Chassis / ABS/VSC/TRC / Utility / Air Bleeding.
    
    Tech Tips
    
    Refer to the intelligent tester operator's manual for further details.
  5. Bleed the front right brake line.
    
    Note
    
    Make sure that the master cylinder reservoir does not run out of brake fluid.
    
    1. Select "FR Line" on the intelligent tester.
    
    2. Loosen the bleeder plug.
    
    3. Depress the brake pedal and hold it.
    
    Note
    
    The actuator operation stops automatically in 4 seconds.
    
    4. Tighten the bleeder plug completely.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
    
    5. Release the brake pedal.
    
    6. Wait 20 seconds.
    
    7. Repeat the steps above until there are no more air bubbles in the fluid.
  6. Bleed the front left brake line.
    
    Note
    
    Make sure that the master cylinder reservoir does not run out of brake fluid.
    
    1. Select "FL Line" on the intelligent tester.
    
    2. Loosen the bleeder plug.
    
    3. Depress the brake pedal and hold it.
    
    Note
    
    The actuator operation stops automatically in 4 seconds.
    
    4. Tighten the bleeder plug completely.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
    
    5. Release the brake pedal.
    
    6. Wait 20 seconds.
    
    7. Repeat the steps above until there are no more air bubbles in the fluid.
  7. Bleed the rear right brake line.
    
    Note
    
    Make sure that the master cylinder reservoir does not run out of brake fluid.
    
    1. Select "RR Line" on the intelligent tester.
    
    2. Loosen the bleeder plug.
    
    3. Depress the brake pedal and hold it.
    
    Note
    
    The actuator operation stops automatically in 4 seconds.
    
    4. Tighten the bleeder plug completely.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
    
    5. Release the brake pedal.
    
    6. Wait 20 seconds.
    
    7. Repeat the steps above until there are no more air bubbles in the fluid.
  8. Bleed the rear left brake line.
    
    Note
    
    Make sure that the master cylinder reservoir does not run out of brake fluid.
    
    1. Select "RL Line" on the intelligent tester.
    
    2. Loosen the bleeder plug.
    
    3. Depress the brake pedal and hold it.
    
    Note
    
    The actuator operation stops automatically in 4 seconds.
    
    4. Tighten the bleeder plug completely.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
    
    5. Release the brake pedal.
    
    6. Wait 20 seconds.
    
    7. Repeat the steps above until there are no more air bubbles in the fluid.
  9. Disconnect the intelligent tester from the DLC3.
4. Clear the DTCs Click here.
5. Inspect for brake fluid leak.
6. Inspect fluid level in reservoir Click here.
BLEED AIR FROM CLUTCH LINE (for 1ZR-FAE with Manual Transaxle)
Text in Illustration

*1 Bleeder Plug Cap

*2 Bleeder Plug
1. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
  
  Brake fluid
  
  SAE J1704 or FMVSS No, 116 DOT 4
2. Remove the bleeder plug cap.
3. Connect a vinyl tube to the bleeder plug.
4. Depress the clutch pedal 5 times, and then loosen the bleeder plug while the pedal is depressed.
5. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.
6. Repeat both of the previous 2 steps 6 times.
7. Tighten the bleeder plug.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
8. Depress the clutch pedal 10 times or more and confirm its operation.
  
  Note
  
  This must be performed before the engine is started.
9. Install the bleeder plug cap.
10. Check that all the air has been bled from the clutch line.
BLEED AIR FROM CLUTCH LINE (for 2ZR-FAE with Manual Transaxle)
Text in Illustration

*1 Bleeder Plug Cap

*2 Bleeder Plug
1. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
  
  Brake fluid
  
  SAE J1704 or FMVSS No, 116 DOT 4
2. Remove the bleeder plug cap.
3. Connect a vinyl tube to the bleeder plug.
4. Depress the clutch pedal 5 times, and then loosen the bleeder plug while the pedal is depressed.
5. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.
6. Repeat both of the previous 2 steps 6 times.
7. Tighten the bleeder plug.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
8. Depress the clutch pedal 10 times or more and confirm its operation.
  
  Note
  
  This must be performed before the engine is started.
9. Install the bleeder plug cap.
10. Check that all the air has been bled from the clutch line.
BLEED AIR FROM CLUTCH LINE (for 1AD-FTV with Manual Transaxle)
Text in Illustration

*1 Bleeder Plug Cap

*2 Bleeder Plug
1. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
  
  Brake fluid
  
  SAE J1704 or FMVSS No, 116 DOT 4
2. Remove the bleeder plug cap.
3. Connect a vinyl tube to the bleeder plug.
4. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.
5. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.
6. Repeat the previous 2 steps until all the air in the fluid is completely bled.
7. Tighten the bleeder plug.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
8. Install the bleeder plug cap.
9. Check that all the air has been bled from the clutch line.
BLEED AIR FROM CLUTCH LINE (for 2AD-FHV with Manual Transaxle)
Text in Illustration

*1 Bleeder Plug Cap

*2 Bleeder Plug
1. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
  
  Brake fluid
  
  SAE J1704 or FMVSS No, 116 DOT 4
2. Remove the bleeder plug cap.
3. Connect a vinyl tube to the bleeder plug.
4. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.
5. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.
6. Repeat the previous 2 steps until all the air in the fluid is completely bled.
7. Tighten the bleeder plug.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
8. Install the bleeder plug cap.
9. Check that all the air has been bled from the clutch line.
INSTALL CENTER COWL TOP VENTILATOR LOUVER
1. Attach the 5 claws to install the center cowl top ventilator louver.
2. Push the clip to attach it, and then slide the hood to cowl top seal as shown in the illustration to attach the claw.
INSTALL FRONT WHEEL

Torque:

103 N*m { 1050 kgf*cm, 76 ft.*lbf }

Text in Illustration
*1	Lithium soap base glycol grease

Brake fluid
SAE J1704 or FMVSS No, 116 DOT 4

Text in Illustration
*1	Bleeder Plug Cap
*2	Bleeder Plug

Brake fluid
SAE J1704 or FMVSS No, 116 DOT 4

Text in Illustration
*1	Bleeder Plug Cap
*2	Bleeder Plug

Brake fluid
SAE J1704 or FMVSS No, 116 DOT 4

Text in Illustration
*1	Bleeder Plug Cap
*2	Bleeder Plug

Brake fluid
SAE J1704 or FMVSS No, 116 DOT 4

Text in Illustration
*1	Bleeder Plug Cap
*2	Bleeder Plug

Brake fluid
SAE J1704 or FMVSS No, 116 DOT 4

INSPECT AND ADJUST BRAKE PEDAL HEIGHT

Text in Illustration
*1	Stop Light Switch
*2	Clevis Lock Nut
*3	Floor Panel

Check the brake pedal height.

Pedal Height from Floor Panel

for LHD
Item	Specified Condition
for Automatic Transaxle and CVT	148.5 to 158.5 mm (5.85 to 6.24 in.)
for Manual Transaxle	148.5 to 158.5 mm (5.85 to 6.24 in.)

for RHD
Item	Specified Condition
for Automatic Transaxle and CVT	131.5 to 141.5 mm (5.18 to 5.57 in.)
for Manual Transaxle	132.2 to 142.2 mm (5.20 to 5.60 in.)

Adjust the brake pedal height.
1. Disconnect the stop light switch connector.
2. Remove the stop light switch assembly.
3. Loosen the push rod clevis lock nut.
4. Adjust the brake pedal height by turning the push rod.
5. Tighten the push rod clevis lock nut.
  
  Torque:
  
  22 N*m { 224 kgf*cm, 16 ft.*lbf }
6. Insert the stop light switch into the adjuster mounting until the switch body touches the brake pedal.
  
  Note
  
  Do not depress the brake pedal.
7. Turn the switch a quarter turn clockwise.
  
  Torque:
  
  1.5 N*m { 15 kgf*cm, 13 in.*lbf, or less }
  
  Note
  
  Do not depress the pedal.
8. Connect the connector to the switch.
9. Check the switch clearance.
  
  Stop light switch clearance
  
  0.5 to 2.6 mm (0.0197 to 0.102 in.)

INSPECT BRAKE PEDAL FREE PLAY
1. Stop the engine. Depress the brake pedal several times until no vacuum is left in the brake booster. Release the brake pedal.
2. Depress the pedal until a slight resistance is felt. Measure the distance as shown in the illustration.
  
  Pedal free play
  
  1.0 to 6.0 mm (0.0394 to 0.236 in.)
  
  If the pedal free play is not as specified, check the stop light switch clearance.
INSPECT BRAKE PEDAL RESERVE DISTANCE

Tech Tips

Measure the distance from the same point used for the brake pedal height inspection.
1. Release the parking brake.
2. With the engine running, depress the brake pedal and measure the pedal reserve distance.
  
  Pedal Reserve Distance from the Floor Panel at 294 N (30 kgf, 66 lbf)
  
  87 mm (3.43 in.)
  
  If the distance is not as specified, troubleshoot the brake system Click here.